Coating composition containing kauri resin



Patented Sept. 14, 1943 UNITED STATES PATENT OFFICE, 7

COATING COMPOSITION CONTAINIL G KAURI RESIN Robert C. Swain, Riverside, and Pierrepont Adams, Stamford, Conn., assignors'to American Cyanamid Company, New York, N. Y.. a corporationioi' Maine No Drawing. Application November 26, 1940,

. Serial No. 367,221

4 Claims.

This invention relates to coating compositions containing kauri resin and melamineformaldehyde resins.

An object of this invention is to improve the physical and chemical properties of coating compositions containing kauri resin, e. g., acid resistance, water resistance, solvent resistance, heat Example 1 Parts Melamine-formaldehyde resin A Kauri res 90 A composition containing these ingredients is prepared by admixing 20 parts of melamineformaldehyde resin A solution (50% resin) with 360 parts of fKauri resin stock solution (containing 25% of kauri resin and 75% of the monoethyl ether of ethylene glycol (Cellosolve)). Films of the composition are applied to metal objects and baked at a temperature of about 135 C. for about one-half hour. The product is a hard, transparent coating having good film strength.

Example 2 Parts Melamine-formaldehyde resin B 25 Kauri res n '75 A composition containing these ingredients is prepared by admixing 50 parts of melamineformaldehyde resin "13 solution (50% resin) with 300 parts of Kauri resin stock solution. Films of the composition are applied to metal objects and baked at a temperature of about 135 C. for about one-half hour. A film having excellent properties such as water resistance is formed.

Example 3 V Parts -Melamine-formaldehyde resin C 50 Kauri res 50 A composition containing these ingredients I is prepared by admixing parts or melamineiormaldehyde resin- C solution (50% resin) with 200 parts of Kauri resin stock solution.

Films of the composition are applied to metal objects and baked at a temperature of about C. for about one-half hour. A water-white film having good chemical properties is formed.

Example 4 Parts Melamine-formaldehyde resin B 75 Kauri res 25 A composition containing these ingredients is prepared by admixing parts of melamineformaldehyde resin B solution (50% resin) with 100 parts of Kauri resin stock solution. Films of the composition are applied to metal objectsand baked at a temperature of about 135 C. for about one-half hour. A clear, tough film is formed.

Ewwmple 5 Parts Melamine-formaldehyde resin A; 90 Kauri resin- 10 A composition containing these ingredients is prepared by, admixing parts of melamine-- formaldehyde resin A solution (50% resin) with 40 parts of Kauri resin stock solution. Films of the composition are applied to metal objects and baked at a temperature of about 135 C.

for about one-half hour. The product is a clear, water-white film which is extremely mar-resistant.

Example 6 Parts Melamine-formaldehyde resin D 10 Kauri resm 90 A composition containing these ingredients is prepared by admixing 20 parts of melamineformaldehyde resin D solution (50% resin) with 360 parts of Kauri resin stock solution." Films of the composition are applied to metal objects and baked at a temperature of about 135 C. for about one-half hour. The product formed is a very hard, clear coating.

Example 7 Parts Melamine-formaldehyde resin E 25 Kauriresi '15 i A composition containing these ingredients is prepared by admixing 50 parts of melamineformaldehyde resin E solution (50% resin) with 300 parts of Kauri resin stock solution. Films of the composition are applied to metal objects and baked at a temperature of about 135 C. for about one-half hour. The product is a transparent, resistant coating.

' Example 8 Parts Melamine-formaldehyde resin 'F 50 Kauri resin 50 Example 9 7 Parts Melamine-formaldehyde resin G '15 Kauri res 25 A composition containing these ingredients is prepared by admixing 150 parts of melamineformaldehyde resin G solution (50% resin) with 100 parts of Kauri resin stock solution. Films of the composition are applied to metal objects and baked at a temperature of about 135 C. for about one-half hour. A hard, transparent film is produced.

Example 10 Parts Melamine-formaldehyde resin D 90 Kaurl res Y 10 A composition containing these ingredients is prepared by admixing 180 parts of melamineformaldehyde resin D solution (50% resin) with 40 parts of Kauri resin stock solution." Films of the composition are applied to metal objects and maked at a temperature of about 135 C. for about one-half hour, to give a smooth transparent surface.

Preparation of melamine-formaldehyde resin A Parts Melamine (1 mol) 126 Formalin (4 mols) (37% formaldehyde in water) 324.4 n-Butanol 440 This mixture is placed in a reflux apparatus which is provided with a condenser and a suitable water trap through which the reflux condensate passes on its return to the reaction chamber and in which the essentially aqueous fraction of the condensate may be separated from the essentially non-aqueous fraction and means is provided so that the former fraction may be drawn 011 if desirable. The reaction mixture is refluxed at a temperature of about 91-93" C. at atmospheric pressure for 6-12 hours. The water is removed by azeotropic distillation from the reaction mixture during the reflux operation beginning preferably after about 2-5 hours have elapsed and the water so removed is separated from the reflux condensate in the water trap. During the distillation about 550 additional parts of butanol are added gradually. When the reflux condensate is substantially anhydrous the vapor temperature will be about 100-105 C. The pressure is lowered sufliciently to reduce the vapor temperature to about 85-90 7C. and the resin solution is concentrated to about 60-70% solids by vacuum distillation. The resulting resin solution may be diluted to about 50% solids with any desired solvent or diluent,

e. g., xylene.

Preparation of melamine-formaldehyde resin B Parts Melamine (1 mol) 126 Formalin (5 mols) (37% formaldehyde in water) 1 405.5 n-Butahol 440 This mixture is placed in' a reflux apparatus which is provided witha condenser and a suitable water trap through which the reflux condensate passes on its return to the reaction chamber and in which the essentially aqueous fraction of the condensate may be separated from the essentially non-aqueous fraction and means is provided so that the former fraction may be drawn off is' desirable. The reaction mixture is refluxed at a temperature of about 91-93 C. at atmospheric pressure for 6-12 hours.

The water is removed by azeotropic distillation. from the reaction mixture during the reflux operation beginning preferably after about 2-5 hours have elapsed and the water so removed is separated from the reflux condensate in the water trap. During the distillation about 550 additional parts of butanol are added gradually.

When the reflux condensate is substantially anhydrous the vapor temperature will be about 100-105 C. The pressure is lowered sufliciently to reduce the vapor temperature to about 85-90 C. and the resin solution is concentrated to about 60-70% solids by vacuum distillation. The resulting resin solution may be diluted to about solids with any desired solvent or diluent, e. g., xylene.

This mixture is placed in a reflux apparatus which is provided with a condenser and a suitable water trap through which the reflux condensate passes on its return to the reaction chamber and in which the essentially aqueous fraction of the condensate may be separated 5 from the essentially non-aqueous fraction and -means is provided so that the former fraction may be drawn 011' if desirable. The reaction mixture is refluxed at a temperature of about 91-93 C. at atmospheric pressure for 6-12 hours. The water is removed by azeotropic distillation from the reaction mixture during the reflux operation beginning preferably after about 2-5 hours have elapsed and the water so removed is separated from the reflux condensate in the water trap. During the distillation about 550 additional parts ofbutanol are added gradually. When the reflux condensate is substantially anhydrous the vapor temperature will beabout Y 100-105 C. The pressure is lowered sufliciently to reduce the vapor temperature to about 85-90 C. and the resin solution is concentrated to about -70% solids by vacuum distillation. The resulting resin solution may be diluted to about 50% solids with any desired solvent or diluent,

e. g., xylene.

Preparation of melamine-formaldehyde resin "D Parts Melamine 283 Formalin (37% formaldehyde in water) 978 then 320 partsof methanol are added. Wet

methanol is gradually distilled ofl? from the mixture and drymethanol is added at about the same rate as wet methanol is distilled off. This distillation and addition of methanol is continued until the distillate is substantially dry methanol. During this operation which requires about 4 hours, about 1600 parts of methanol are added. 707 parts of Pentasol (trade name of SharplesSolvents Corporation for mixed amyl alcohols) are added and the distillation is continued until the vapor temperature rises to about IOU-105 C. Aboutfi 10 parts of the distillate are collected. The pressure is lowered sufficiently to reduce the temperature to 80-90 C. and 178 parts more of the distillate are collected, leaving as a product a resin solution containing 50% of resin solids in Pentasol.

Preparation of melamine-formaldehyde resin E Parts Melamine (1 mol) 126 Formalin (5 mols) (37% formaldehyde in water) 405.5 n-Hexyl alcohol 500 Methyl alcohol 200 This mixture is placed in a reflux apparatus which is provided with a condenser and a suitable water trap through which the reflux condensate passes on its return to the reaction chamber and in which the essentially aqueous fraction of the condensate may be separated from the essentially non-aqueous fraction and means is provided so that the former fraction may be drawn ofi if desirable. The reaction mixture is refluxed at a temperature of about 80-85 C. at atmospheric pressure for 6-12 hours. The water is removed by azeotropic distillation from the reaction mixture during the reflux operation beginning preferably after about 2-5 hours have elapsed and the water so removed separated from the reflux condensate in the we.-

, Preparation of melamine-formaldehyde resin F Parts Melamine-formaldehyde (molal ratio 1:4:

' spray-dried powder 2th 2-ethyl hexanol 280 n-Butanol 320 Methyl acid phosphate a The melamine-formaldehyde condensation product is obtained by refluxing melamine and formalin (37% formaldehyde in water) in the molal ratio of 1:4 at a pH of about 7-9 for about 5 3 hours and then spray-drying.

The spray-dried melamine-formaldehyde powder, octanol, butanol and methyl acid phosphate are heated to about 100-105" C. in 30 minutes and refluxed about 30 minutes. This solution is vacuum concentrated at about 50-70" C-. to form a product containing about 50% solids.

Preparation 0] melamine-formaldehyde resin G Parts 1 Melamine (1 mol) 126 Formalin (5 mols) (37% formaldehyde in water) 405.5 Benzyl alcohol 600.

This mixture is placed in a reflux apparatus which is provided with a condenser and a suitable water trap through which, the reflux condensate passes on its return to the reaction chamber and in whichthe essentially aqueous fracr tion of the condensate may be separated from the essentially non-aqueous fraction and means .is provided so that the former fraction may be drawn oflE if desirable. The reaction mixture is refluxed at a temperature of about 93-95 C. at

sulting resin solution may be diluted to about 50% solids with any desired solvent or diluent, e. g., xylene.

Alblatd melamine-formaldehyde resins may be produced in accordance with the procedures outlined above, as well as in any other suitable manner. Aqueous syrups of melamine-formaldehyde resins may be first produced and then alkylated either simultaneously with dehydration or subsequent to dehydration. Generally the simultaneous condensation of melamine, formaldehyde and a suitable alcohol is used because of convenience. in order to facilitate the alkylation with the higher alcohols, e. 8., the amyl alcohols, the hexyl alcohols and the octanols, a low boiling alcohol such'as methanol or butanol may be mixed with the higher alcohol, thereby assisting in rezrzcving the water and causing the reaction to take place readily at somewhat lower temperatures than would otherwise be required.

iv boiling alcohol is removed by distillaaiter the reaction is completed. Another method for producing resins alkylated with higher alcohols is to alkylate the melamine-formaldehyde resin with a low boiling alcohol such as methanol and subsequently replacing it with the desired higher alcohol, distilling out the low boilin: alcohol. The condensation may be carried out either with or without an acid catalyst and in some instances basic catalysis may desirably The melamine-formaldehyde resins vary slightly according to minor variations in control d ringtheirproductionandinsmncinstan es small 75 proportions of a suitable solvent material, e. 8-.

iii!

turpentine, ethanol, benzene, the monoethyl ether of ethylene glycol (Cellosolve) etc., may be added to .the original solutions of kauri resin and melamine-formaldehyde resin in order to produce perfectly clear solutions if such solutions are not originally obtained.

While formaldehyde has been used in the previous examples, it will be obvious that the various polymers of formaldehyde, e. g., paraformaldehyde,' or substances which yield formaldehyde may be used in place of part or all of the formaldehyde.

As indicated by the above examples kauri resin has been found to be compatible with melamineformaldehyde resins wherein the molal ratio of formaldehyde to melamine is at least about 2.5:1. Butylated melamine-formaldehyde resins wherein the molal ratio of formaldehyde to melamine is about 2.5:1 may be substituted for part or all of the melamine resins used in the above examples. Such resins may be produced by reacting the melamine resins with methanol and subsequently replacing the methanol with butanol. Melamine-formaldehyde resins which are alkylated with propyl alcohol and.;wherein the molal ratio of formaldehyde to melamine is about 4:1 are compatible in proportions greater than about 80%. On the other hand, melamineformaldehyde resins which arealkylated with ethylene chlorohydrin wherein the molal ratio of formaldehyde to melamine is about 5.5:1 are the resin to be cured at lower temperatures than indicated in the above examples. Such substances are, for instance,.phosphoric acid, ammonium salts of phosphoric acid, etc.

Other resinous compositions may be included in various coating compositions, e. g., urea-formaldehyde resins, phenol-formaldehyde resins, alkyd resins, ethyl cellulose, cellulose acetate, nitrocellulose, etc., as well as in varnishes, especially linseed oil and tung oil varnishes.

' Our mixed products show improved solvent resistance, acid resistance, water resistance, resistance to chemicals such as bromine; chlorine and the like, etc., as compared to kauri-resin compositions not containing melamine-formaldehyde resins. Similarly melamine-formaldehyde resins decrease the thermoplasticity of the kauri resin. Our products find use in varnishes, paints. japans, enamels, lacquers, etc. in the manufacture of linoleum, oil cloth, as well as for impregnating paper and fabric, particucompatible only in proportions less .than about 20%. While higher ratios of formaldehyde to melamine than 6:1 may be used, it is generally undesirable inasmuch as formaldehyde is lost during the curing so that usually the product in its cured condition does not contain more than about 6 mols of formaldehyde to 1 mol of melamine. The percentage composition in each instance in this'paragraph is on a total solids weight basis.

The resins may be alkylated with any of the straight chain or branched chain alcohols containing at least 4. carbon atoms, as well as with aralkyl types of alcohols such as benzyl alcohol. The term alkylated melamine-formaldehyde resin is intendedto denote compositions which are reacted with an alcohol.

Our products may be plasticized with a wide variety of materials such as the alkyl phthalates, tricresyl phosphate, various alkyd resins, particularly the fatty oil acid modified alkyd resins, etc.

be added to our compositions, e. g., lithopone,

Various fillers, pigments, dyes and lakes may zincoxide, titanium oxide, ferric oxide, Prussian larly for use as electrical insulation.

The term compatible as used herein is intended to denote compositions, films of which are clear and homogeneous after baking,

Obviously many modifications and variations in the processes and compositions described above may be made without departing from the spirit and scope of the invention as defined in the appended claims.

We claim:

1. A coating composition containing substantial amounts of kauri resin and a melamineformaldehyde resin which has been alkylated with an alcohol containing atleast 4 carbon atoms, wherein the molal ratio of formaldehyde to melamine is at least about 25:1 and wherein the weight ratio of kauri resin to melamine resin is between about 9:1.and 1:9.

2. A coating composition containing substantial amounts of kauri resin and a melamineformaldehyde resin which has been alkylated with n-butanol and wherein the molal ratio of formaldehyde to melamine is at least about 2.5:1 and wherein the weight ratio of kauri resin to melamine resin is between about 9:1 and 1:9.

3. A coating composition containing substantial amounts of kauri resin and a melamineformaldehyde resin which-has been alkylated with n-hexanol and wherein the molal. ratio of formaldehyde to melamine is at least about 2.5:].

and wherein the weight ratio of kauri resin to melamine resin is between about 9:1 and 1:9.

4. A coating composition containing substantial amounts of kauri resin and a melamineformaldehyde resin which has been 'alkylated with benzyl alcohol and wherein the molal ratio of formaldehyde to melamine is at, least about 25:1 and wherein the weight ratio of kauri resin to melamine resin is between about 9:1 and 1:9.

. ROBERT C. SWAIN.

PIERREPONT ADAMS.

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